Shoelace and method of manufacture

ABSTRACT

A lace providing reduced slippage employs a set of compact outwardly protruding knobs attached, for example, by adhesion that operate to reduce slippage between the lace portions in a bow or at a point of passage through an islet through flexibility of the underlying lace.

CROSS REFERENCE TO RELATED APPLICATION

This Application claims the benefit of U.S. Provisional Application63/168,145 filed Mar. 30, 2021, and hereby incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTBACKGROUND OF THE INVENTION

The present invention relates to laces, for example, as used as closuredevices for shoes and the like and in particular to laces that betterresist untying, and a method of manufacture of these laces.

There are about 2 billion pairs of shoes sold each year. With theexception of slip-on shoes and other lace-less shoes, most users arefamiliar with the inconvenience and potential hazard of shoelacesbecoming untied. Whether the shoes in question are used for performance,competition, or leisure it is a universal problem.

This problem has been addressed in the prior art by providing a shoelacethat, either through a weaving technique or the insertion of elasticmaterials inside the shoelace, provides a set of regularly spaced bulgesin the shoelace that tend to catch against other portions of theshoelace in a bow or when the shoelace passes through the shoe eyelets.The laces are relatively difficult to manufacture, requiring a change inthe manufacture of the shoelaces themselves thus greatly limitingshoelace options. Elastic or elastomeric materials used in theseproducts can fatigue over time and lose their effectiveness.

SUMMARY OF THE INVENTION

The present inventors have recognized that a set of relatively compactoutwardly extending knobs adhered to the shoelace can substantiallyreduce slipping and untying of the shoelace. The knobs may be relativelycompact to be readily applied to the surface of the shoelace in themanufacturing operation with the compact size of the knobs operatingtogether with the flexibility of the shoelace to provide sufficientresilience without the need for an elastomeric material. The outersurface of the knob may be substantially dome-shaped to provideresistance without excessive catching of the eyelets of the shoes.

More specifically, in one embodiment, the invention provides aslip-resistant lace having a lace body of flexible woven materialextending in an axial direction between a first and second endterminating in at least one aglet defining an inner and outer surface ofthe lace body. A plurality of knobs of nonwoven material are integratedon the outer surface of the lace body and extend outwardly therefrom,the knobs having a width perpendicular to the axial direction less thanone half a circumferential perimeter of the lace body.

It is thus a feature of at least one embodiment of the invention toprovide improved resistance to lace untying and slippage by employingthe natural resilience of the lace together with the knob to provide astructure that can resist but not prevent the passage of the lacethrough the eyelets or in sliding contacts with other portions of thelace in a bow or knot.

The knobs may be attached by adhesion to the outer surface of the lacebody.

It is thus a feature of at least one embodiment of the invention toprovide a lace that can be readily manufactured without the need forfundamental pre-manufacture modification of existing lace stock or lacemanufacturing techniques.

The lace body may be a tube, and the knobs may adhere to the outersurface of the lace body so as to allow the tube to attain a circularcross-section.

It is thus another feature of the invention to preserve the flexibilityof the lace with respect to allowing flexible inward displacement of theknobs.

The knobs may have a substantially dome-shaped outer surface.

It is thus another object of the invention to provide knobs that resistsliding by the need to flex the knob inward rather than primarily fromfriction or catch-points on the surface of the knob.

The knobs may be a polymer material attached to the lace body, forexample, a UV curable polymer.

It is thus a feature of at least one embodiment of the invention toeliminate the need for complex manufacturing steps by employing a knobmaterial that can be readily attached to an outer surface of the lacethrough simple extrusion.

In some embodiments, the knobs maybe a non-elastomeric polymer, such asan acrylate material.

It is thus a feature of at least one embodiment of the invention toprovide a durable and smooth outer surface to the knobs that allows theresistance of the knobs to be primarily through a flexure rather thanfriction.

The knobs may comprise a first set on one side of the lace body and asecond set on an opposite side of the lace body. In some embodiments thefirst and second sets are axially staggered.

It is thus a feature one embodiment of the invention to permit anincreased axial density of knobs to ensure interference between knobsand other portions of the laces or eyelets at the desired position ofthe lace while preserving the flexibility of the lace beneath the knobs.

The lace may be manufactured by applying a UV curable adhesive to anouter surface of the lace body at regular locations along an axiallength of the lace body and applying a UV light to cure the adhesive toform the knobs.

It is thus a feature of at least one embodiment of the invention toprovide a manufacturing technique that may make use of a liquid materialthat will naturally dome to a smooth outer shape which may then behardened by ultraviolet light.

These particular objects and advantages may apply to only someembodiments falling within the claims and thus do not define the scopeof the invention.

DETAIL DRAWINGS OF THE INVENTION

FIG. 1 is a system overview for the method of the present invention.

FIG. 2 is a production flow chart for the method of the presentinvention.

FIG. 3 is a perspective view of an embodiment for the components of thesystem for the method of the present invention.

FIG. 4 is a perspective fragmentary view of a lace constructed accordingto at least one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 4, a lace 10 may provide a lace body 11 extendingalong an axial direction 12 between first and second ends 14 a and 14 band may include an aglet 16 on those ends 14 preventing unraveling ofthe material of the lace body 11. The lace body 11 may use structuressuch as flat laces, braided laces, tubular laces, or round laces. Thematerial of the lace body 11 may be a variety of different materialsincluding spun cotton, woven cord, polyester and aramid blend, flattubular polyester braid, round braided polyester, spun polyester, spunnylon, nylon, Taslan, Cardura, and waxed cotton.

Attached to an outer surface of the lace body 11 are a set of axiallyspaced outwardly extending knobs 18 applied in a first set 20 a on afirst side of the lace body 11 in a first axial line and a second set 20b on a second side of the lace body 11 extending in a second axial linepositioned in diametric opposition to the first axial line about theaxis of the lace body 11.

Each of the knobs 18 may be spaced axially by a distance 22 at leastfour times the axial length 24 of the knob 18, and the knobs 18 may havea circumferential width 26 less than half the circumferential peripheryof the lace body 11. This allows sufficient lace material to serve as aflexible substrate for the knobs 18 allowing the knobs 18 to beconstructed of a substantially rigid and non-elastomeric material whilehaving a substantial outward interfering detent surface. In this regard,the knobs 18 of the set 20 a may be offset axially from the knobs 18 ofthe set 20 b by half the distance 22.

In one embodiment, the knobs 18 may have an outer dome shape(approximating a spherical dome) and may be constructed of asubstantially rigid or non-elastomeric material such as a thermoplasticor thermoset material or ultraviolet curable material. In one embodimentthe knobs 18 may be constructed of a UV curable adhesive, for example, anon-elastomeric acrylate commercially available under the trade nameVT249 (Vibra-TITE UV® adhesive) commercially available from NDIndustries of Clawson, Michigan. This adhesive may be applied in aliquid form to naturally generate a smooth dome and to adhere and infuseto the lace body 11, yet without attaching together the opposed walls ofa tube of the lace 10 thereby preserving the natural flexibility of thelace 10 outside of the immediate contact with the knob 18.

The following portion of the document focuses on the overall steps andorder of steps for the custom manufacturing method. After the method isdisclosed, the latter portion of the document discusses further detailin regard to the components involved in the custom manufacturing processand the resulting product of such manufacturing method.

For the preferred embodiment of the custom manufacturing method, first alace is fed from a box and/or spool through a first print head, wherethe first print head applies a plurality of knobs 18 on the first sideof the lace 10. The first print head applies the plurality of knobs 18at a production speed of 60 feet per minute.

Next, the lace traverses through a UV tunnel station which cures eachknob 18 from the plurality of knobs of the first side of the lace at arate of one inch per five seconds at a 50 percent intensity.

Then, the lace 10 traverses through rollers which are connected to alinear servo controlled drive with an encoder to flip the lace andprepare for printing on the second side.

The linear servo controlled drive with an encoder determines thestaggered print position. Lastly, the plurality knobs 18 are applied onthe second side of the lace 10 via the second print head. The lace thentraverses back through the UV tunnel station for curing of the pluralityof knobs from the second side of the shoelace. The lace 10 thentraverses back to the exit location where the lace 10 is deposited intoa box and/or spool.

The aforementioned steps for the preferred embodiment of the custommanufacturing method are not limited by the aforementioned description.Therefore, any variation which is an obvious modification of the stepsand/or components disclosed in the aforementioned description is stillto be considered within the scope of the present invention.

It is important to note that the preferred embodiment for the presentinvention comprises a Nordson Jet spray system dispensing head for thefirst print head and the second print head.

The Nordson Jet spray system printer head and all relating matters isbest seen in U.S. Pat. No. 10,022,744, U.S. Pat. App. No. 2016/0339467,and U.S. Pat. App. No. 2016/0339471 all hereby incorporated byreference. As noted in these applications, the printer head may printviscous materials including epoxies, cyanoacrylate, and UV curableadhesives.

The scope of the present invention is not limited to such arrangement orconfiguration. Therefore, any dispensing head which fulfillsmanufacturing, client, and/or design requirements is considered to bewithin the scope of the present invention. Similarly, if a differentdispensing is implemented and the production speed changes from 60 feetper minute, the new production speed is also considered to be within thescope of the present invention.

Furthermore, it is important to note that the UV light tunnel stationfunctions as a curing station with 12 to 14 standard UV lamps. However,the configuration for the UV tunnel station is not limited to sucharrangement and may comprise a different number of standard UV lampsarranged as best to fulfill manufacturing, user, and/or designrequirements.

Lastly, an embodiment of the final product from the custom manufacturingmethod is best seen in FIG. 4. However, it is important to note that thelocation of the knobs from the plurality of knobs on the first side andsecond side of the lace are subject to variance. Meaning, the locationof the knobs from the plurality of knobs is controlled by modifyingparameters within the aforementioned components. Thus, themeasurement/location of knobs with respect to each other does not limitthe scope of the present invention.

FIGS. 1-4 are simply intended for the purpose of depicting andillustrating and the present invention. Therefore, the accompanyingfigures do not limit the scope of the application in any way.

The invention has been explained in relation to its preferredembodiment, but it is to be understood that many other possiblemodifications and variations can be made without departing from thespirit and scope of the invention. Obvious changes, modifications, andsubstitutions may be made by those skilled in the art to achieve thesame purpose of the invention.

Generally, in one embodiment, the present invention aims to preventshoelaces from becoming untied while also being the most user-friendlyshoelace available. The present invention avoids shoelaces inadvertentlybecoming untied, provides a true custom fit, and adds an attractivefashion feature. However, it is not only important to design and createa product which provides a solution to the aforementioned problem. It isalso important to create a manufacturing method which is specificallydesigned to efficiently and effectively produce as many of the disclosedshoelaces as possible.

The exemplary embodiments are merely examples and are not intended tolimit the scope of the invention. It is intended that the presentinvention cover all other embodiments that are within the scope of theappended claims and their equivalents.

The term acrylate material is intended to include but not be limited tocyanoacrylate adhesives and acrylic resins.

Certain terminology is used herein for purposes of reference only, andthus is not intended to be limiting. For example, terms such as “upper”,“lower”, “above”, and “below” refer to directions in the drawings towhich reference is made. Terms such as “front”, “back”, “rear”, “bottom”and “side”, describe the orientation of portions of the component withina consistent but arbitrary frame of reference which is made clear byreference to the text and the associated drawings describing thecomponent under discussion. Such terminology may include the wordsspecifically mentioned above, derivatives thereof, and words of similarimport. Similarly, the terms “first”, “second” and other such numericalterms referring to structures do not imply a sequence or order unlessclearly indicated by the context.

When introducing elements or features of the present disclosure and theexemplary embodiments, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of such elements orfeatures. The terms “comprising”, “including” and “having” are intendedto be inclusive and mean that there may be additional elements orfeatures other than those specifically noted. It is further to beunderstood that the method steps, processes, and operations describedherein are not to be construed as necessarily requiring theirperformance in the particular order discussed or illustrated, unlessspecifically identified as an order of performance. It is also to beunderstood that additional or alternative steps may be employed.

It is specifically intended that the present invention not be limited tothe embodiments and illustrations contained herein and the claims shouldbe understood to include modified forms of those embodiments includingportions of the embodiments and combinations of elements of differentembodiments as come within the scope of the following claims. All of thepublications described herein, including patents and non-patentpublications, are hereby incorporated herein by reference in theirentireties

To aid the Patent Office and any readers of any patent issued on thisapplication in interpreting the claims appended hereto, applicants wishto note that they do not intend any of the appended claims or claimelements to invoke 35 U.S.C. 112(f) unless the words “means for” or“step for” are explicitly used in the particular claim.

What we claim is:
 1. A slip-resistant lace comprising: a lace body offlexible woven material extending in an axial direction between a firstand second end terminating in at least one aglet defining an inner andouter surface of the lace body; and a plurality of knobs of nonwovenmaterial integrated on the outer surface of the lace body and extendingoutwardly therefrom, the knobs having a width perpendicular to the axialdirection less than one half a circumferential perimeter of the lacebody.
 2. The slip-resistant lace of claim 1 wherein the knobs ofnonwoven material are attached by adhesion to the outer surface of thelace body.
 3. The slip-resistant lace of claim 2 wherein the lace bodyis a tube and the knobs adhere so as to allow the tube to attain acircular cross-section.
 4. The slip-resistant lace of claim 1 whereinthe knobs have a substantially dome-shaped outer surface.
 5. Theslip-resistant lace of claim 1 wherein the knobs are a polymer materialattached to the lace body.
 6. The slip-resistant lace of claim 5 whereinthe knobs are a UV curable polymer.
 7. The slip-resistant lace of claim5 wherein the knobs are a non-elastomeric polymer.
 8. The slip-resistantlace of claim 5 wherein the knobs are an acrylate material.
 9. Theslip-resistant lace of claim 1 wherein knobs comprise a first set on oneside of the lace body and a second set on an opposite side of the lacebody.
 10. The slip-resistant lace of claim 9 wherein the first andsecond sets are axially staggered.
 11. The slip-resistant lace of claim10 wherein the first and second sets have substantially equal axialspacing and are offset axially by one half of that spacing.
 12. A methodof manufacturing a slip-resistant lace of a type having a lace body offlexible woven material extending in an axial direction between a firstand second end terminating in at least one aglet; a plurality of knobsof nonwoven material integrated on an outer surface of the lace bodyhaving a width perpendicular to the axial direction less than one half acircumferential perimeter of the lace body, the method providing:applying a UV curable adhesive to an outer surface of the lace body atregular locations along an axial length of the lace body; and applying aUV light to cure the adhesive to form the knobs.